Note: Descriptions are shown in the official language in which they were submitted.
LOW WATER CUTOFF SWITCH
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a switch; and more particularly to a switch
designed for applications related to a low water cutoff.
2. Brief Description of Related Art
Figure 1A shows an existing low water cutoff switch, e.g., having an integral
brass base 7 made from solid brass. The existing low water cutoff switch is a
general purpose liquid flow switch sold under the model no. FS250, e.g., by
the
assignee of the instant patent application. See an Instruction Manual (MM-
625C),
entitled "Series FS-250 General Purpose Liquid Flow Switch".
In Figure 1A, the existing low water cutoff switch includes the following
labeled parts/components:
a plastic cover 1;
a micro switch 2;
a switch bracket 3;
a NPT plug;
a grub screw 5;
a pivot 6;
the brass base 7;
a paddle arm 8;
a paddle 9,
an actuating cam 10; and
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an 0-ring 11.
The existing low water cutoff switch is characterized as follows:
- Basic Function:
To transfer oscillatory motion (because of liquid flow in the pipe where
the switch is mounted) into vertical motion, which would actuate the micro
switch 2 through the actuating cam 10 and ON/OFF signaling would be further
passed on from the low cutoff switch to a given system for taking any further
necessary action.
- Existing Problem:
Yielding of pivot mechanism can lead to failure, and
Development of condensation, e.g., when flow switches are used in
chiller applications.
Figure 1B shows part of the existing low water cutoff switch in Figure 1A,
e.g.,
showing how the 0 rings 11 may be configured in part of the existing low water
cutoff
.. switch in relation to the pivot 6. Figure 1C shows the integral brass base
that forms
part of the existing low water cutoff switch in Figure 1A.
In effect, and by way of example, in the existing design the major base
component is made of solid brass. When such a configuration is used in chiller
application, it can result in condensation build-up in the existing low water
cutoff
switch, because of a heat transfer through conduction and convection, which
over
period of time has a tendency to make the flow switch un-operational.
There is a need to provide a better low cut-off switch that does not have such
problems.
SUMMARY OF THE INVENTION
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According to some embodiments, the present invention takes the form of a
new and unique low water cut-off switch assembly featuring a two-part base
assembly having a lower base part and an upper base part.
The lower base part may be made from a metallic material, configured to be
adapted on piping having a fluid flow, and also configured with a central
orifice to
receive a paddle arm that pivots on an axis in response to the fluid flow in
the piping.
The upper base part may be made from a non-metallic material, configured
with a corresponding central orifice to receive the paddle arm, and configured
with a
channel to receive a pivot arm to mount and allow the paddle arm to pivot on
the axis
in order to actuate an ON/OFF switch in response to the fluid flow.
The non-metallic material of the upper base part is configured with a
substantially lower coefficient of heat transfer (i.e., thermal conductivity)
than the
metallic material of the lower base part, so as to substantially reduce (or
minimize)
condensation build-up in the low water cut-off switch, e.g., when the low
water cut-off
switch is used in applications exposed to temperatures below freezing,
including
chiller applications.
In effect, the present invention is based upon the use of a combination of
metal and non-metal parts for reducing condensation in a flow control switch.
With
the new design, by using a non-metal base part in combination with a brass
insert a
major chunk of metal in the overall low water cut-off switch is being reduced,
and
since the non-metal base part is a bad conductor of heat, e.g., compared to
what a
corresponding part/component made of metal material would be (like that in the
prior
art switch (see Figure 1)), the non-metal base part does not allow the
transfer of cold
temperature / negative heat, and hence there is a substantial reduction in
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condensation in the overall low water cut-off switch which helps in increasing
the
operational life of switch.
The present invention may include one or more of the following features:
The lower base part may be made from brass.
The upper base part may be made from DELRIN (which is a
Polyoxymethylene (POM) (acetal, polyacetal, polyformaldehyde), and registered
as a
trademark by E. I. Dupont De Nemours And Company Corporation, 19898 1007
Market St., Wilmington, Delaware)..
The upper base part may be injection molded onto the lower base part and
coupled together so as to form one base piece.
The lower base part may be configured with a coupling rim, and the upper
base part may be configured with a coupling channel to receive the coupling
rim
when the upper base part is injection molded onto the lower base part.
The two-part base assembly may be configured in some combination that
includes the lower base part being made from brass or stainless steel and the
upper
base part being made from DELRIN or Nylon.
The lower base part may be machined, cast or forged when made.
The upper base part may be coupled to the lower base part using bolts,
screws or mechanical fasteners.
The upper base part and the lower base part may be coupled together with an
0-ring in between to prevent leakage.
By way of example, advantages of the new low water cutoff switch design
may include:
- Reduced condensation due to less conductivity of DELRIND as
compared to brass;
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- Reduced material cost and machining operation time;
- Lesser weight; and
- Ease of assembly.
BRIEF DESCRIPTION OF THE DRAWING
The drawing includes the following Figures, not necessarily drawn to scale:
Figure 1 includes Figures 1A to 1C, where Figure 1A is a cross-sectional view
of an existing low water cutoff switch, e.g., having an integral brass base;
where
Figure 1B is an enlarged view of part of the cross-sectional view in Figure
1A, e.g.,
showing the "0" rings configured in part of the existing low water cutoff
switch in
relation to a pivot; and where Figure 1C shows a perspective view of the
integral
brass base that forms part of the existing low water cutoff switch in Figure
1A.
Figure 2 includes Figures 2A and 2B, where Figure 2A is a cross-sectional
view of a new low water cutoff switch, e.g., having a two part base assembly,
according to some embodiments of the present invention; and where Figure 2B is
an
enlarged view of part of the cross-sectional view in Figure 2A, e.g., showing
the "0"
rings configured in part of the new low water cutoff switch in relation to a
pivot.
Figure 3 includes Figure 3A to 3D showing the two part base assembly that
forms part of the new low water cutoff switch, according to some embodiments
of the
present invention, where Figure 3A shows a perspective view of the two part
base
assembly; where Figure 3B shows an exploded view of the two part base
assembly,
e.g., having upper and lower base parts separated; where Figure 3C shows a one
half cross-sectional view of the new two part base assembly, e.g., having
upper and
lower base parts coupled together; and where Figure 3D shows a perspective
view
of a lower brass base that forms part of the two part base assembly.
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Figure 4 includes Figure 4A(1) to 40 showing various options for the two part
base assembly that forms part of the new low water cutoff switch, according to
some
embodiments of the present invention, where Figure 4A(1) shows an exploded
view
of the two part base assembly, e.g., having upper and lower base parts
separated,
and Figure 4A(2) shows an enlarged view of one part of the two part base
assembly,
e.g., for an option having a fastener coupling together upper and lower base
parts;
where Figure 4B(1) shows a perspective view of an upper part of the two part
base
assembly, and Figure 4B(2) shows a perspective view of a lower part of the two
part
base assembly, e.g., for an option having the upper part and the lower part
coupled
together using a permanent adhesive; where Figure 4C(1) shows a one half cross-
sectional view of the two part base assembly, and Figure 4C(2) shows an
enlarged
view of one part of the two part base assembly, e.g., for an option having an
"0" ring
between the upper and lower base parts; and Figure 4D shows a one half cross-
sectional of the two part base assembly.
In the Figures, similar parts are labeled with similar reference numerals.
Moreover, not every part is labelled with a reference numeral and lead line in
every
Figure, so as to reduce clutter in the drawing.
DETAILED DESCRIPTION OF THE INVENTION
Figure 2: Low Water Cutoff Switch
Figure 2 shows a new low water cutoff switch 100, e.g., having a two part
base assembly generally understood to be indicated as 102, according to some
embodiments of the present invention. See also Figures 3-4.
The two-part base assembly 102 may be configured having an upper base
part 107 and a lower base part 117.
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The lower base part 117 may be made from a metallic material, configured to
be adapted on piping (not shown) having a fluid flow, and also configured with
a
central orifice 117a to receive a paddle arm 108 that pivots on an axis in
response to
the fluid flow in the piping.
The upper base 107 part may be made from a non-metallic material,
configured with a corresponding central orifice 107a to receive the paddle arm
108,
and configured with a channel 107b to receive a pivot or pivot arm 106 to
mount and
allow the paddle arm 108 to pivot on the axis in order to actuate an ON/OFF
switch
(e.g. the micro switch 2) in response to the fluid flow. The paddle arm 108
may be
understood to be pivoting on the axis, e.g., along the longitudinal axis of
the pivot
106.
The non-metallic material of the upper base part 107 has a substantially lower
coefficient of heat transfer (i.e., thermal conductivity) than the metallic
material of the
lower base part 117, so as to substantially reduce (or minimize) condensation
build-
up in the low water cut-off switch, e.g., especially when the low water cut-
off switch is
used in applications exposed to temperatures below freezing, including chiller
applications.
In Figure 2, the new low water cutoff switch includes the following labeled
parts/components:
the plastic cover 1 (see Figure 1A);
the micro switch 2 (see Figure 1A);
the switch bracket 3 (see Figure 1A);
the NPT plug 4 (see Figure 1A);
a pivot pin 105;
the pivot 106;
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a circumferential channel 106a;
the upper base part 107, e.g. made from DELRINO;
the lower base part 117, e.g., made from solid brass;
the paddle arm 108;
a paddle 9,
an actuating cam 10;
an 0-ring 11 (see Figure 1A); and
an 0-ring 111.
The lower base part 117 may be made from brass, as well as other suitable
metallic material either now known or later developed in the future. The upper
base
part 107 may be made from DELRINO, as well as other suitable non-metallic
material either now known or later developed in the future. By way of example,
embodiments are envisioned in which the two-part base assembly 102 may be
configured in some combination that includes the lower base part 117 being
made
from brass or stainless steel and the upper base part 107 being made from
DELRINO or Nylon.
The upper base part 107 may be injection molded onto the lower base part
117 and coupled together so as to form one integrated or combined base piece.
The lower base part 117 may be configured with a coupling rim 117b, and the
upper base part 107 may be configured with a coupling channel 107c to receive
the
coupling rim 117b when the upper base part 107 is injection molded onto the
lower
base part 117. The lower base part 117 may be machined, cast or forged when
made.
The upper base part 107 may be coupled to the lower base part 117 using
bolts, screws or mechanical fasteners 120 (Figure 4A(2)) that are passed
through
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suitable openings or cavities 107d in the upper base part 107 and received by
suitable openings or cavities 117c the lower base part 117, e.g., consistent
with that
shown in Figures 3A to 3C and 4A to 4C.
The upper base part 107 and the lower base part 117 may be coupled
together with an 0-ring 122 in between to prevent leakage.
In effect, when compared to the existing design in Figure 1, the basic idea of
the present invention includes using one or more of the following new
features:
- Insert the pivot pin 105 through the pivot 106 in order to provide more
strength to the mechanism (when compared to the grub screw 5 (Figure 1)
which is not inserted through the pivot 6),
- Increase the diameter of pivot pin 105 (when compared to the grub
screw 5 (Figure 1)), and
- Use a metal/non-metal base combination to minimize the
condensation, e.g., in freezer type applications.
Figure 3: The Two Part Base Assembly 102
Figure 3 shows the two part base assembly 102 that forms part of the new low
water cutoff switch, according to some embodiments of the present invention.
In Figure 3, the basic idea of the design according to the present invention
may be summarized, as follows:
The brass base 7 (Figure 1A) has effectively been split into two different
parts,
including the upper base part 107, e.g., which may be made of a non-metallic
material such as DELRIN , and the lower base part 117, e.g., which may be made
of a metallic material such as solid brass. By way of example, when the brass
base
7 in Figure 1A and the two part base assembly 102 are compared, the brass base
7
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has effectively been split into two different halves, including the upper base
part 107
and the lower base part 117. In operation, when the low water cutoff switch is
arranged in relation to the piping (not shown), the lower base part 117 is
generally
understood to be the part immersed within the piping and subject to the
adverse
conditions caused by the liquids flowing in the piping, e.g., including
conditions
related to caustic chemicals flowing in the piping.
The bottom brass part 117 may be machined, and then upper base part may
be formed from DELRINO by injecting it over and above the lower brass part
117, so
that the two parts/pieces become solid and act as one integrated piece.
The design of the combine brass base part/component and DELRIN base
part/component may be made such that they would provide a locking effect
during
the switch's operation under pressure.
The scope of the invention is intended to include using various other
combination of materials for the metal and non-metal combination, e.g.,
including but
not limited to, at least the following:
Stainless steel with DELRINO, or
Stainless steel with Nylon GF (glass-filled nylon), or
Brass with Nylon GE, etc.
Other alternate designs are also envisioned which can be made using this
approach for low water cutoff application within the scope and spirit of the
present
invention.
Figure 4 (Alternative Designs)
Figure 4 includes shows various other alternatives/options/examples for the
two part base assembly 102 that forms part of the new low water cutoff switch,
according to some embodiments of the present invention.
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For example, Figure 4A shows a two part base assembly 102, e.g., for an
option having a fastener 120 coupling together the upper and lower base parts
107,
117.
Further, Figure 4B shows the two part base assembly, e.g., for an option
having the upper base part 107 and the lower base part coupled together using
a
permanent adhesive (not shown). A person skilled in the art would appreciate
and
understand that adhesives are known in the art for coupling a non-metallic
part to a
metallic part, including DELRIN and brass, and the scope of the invention is
not
intended to be limited to any particular type or kind thereof either now known
or later
developed in the future. The adhesive may include a glue, epoxy, etc. that is
either
now known or later developed in the future.
Furthermore, Figure 4C shows the two part base assembly 102, e.g., for an
option having an 0-ring 122 arranged between the metal and non-metal base
parts
so as to avoid probable leakage.
In each option, the upper non-metallic base part 107 may be machined from
bar stock or made using an injection mold process. The lower metallic base
part 117
may be machined, cast or forged. The upper non-metallic base part 107 and the
lower metallic base part 117 may be joined using bolts, screws, mechanical
fasteners like element 120, etc., as well as the adhesive.
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Heat Transfer Coefficient
The heat transfer coefficient in thermodynamics and in mechanics is
understood to be a proportionality coefficient between the heat flux and the
thermodynamic driving force for the flow of heat (i.e., the temperature
difference,
AT):
q"
-
AT
where
q': heat flux, W/m2 i.e., thermal power per unit area, q = dQ/dA
h : heat transfer coefficient, W/(m2=K)
AT : difference in temperature between the solid surface and surrounding fluid
area, K
It is used in calculating the heat transfer, typically by convection or phase
transition
between a fluid and a solid.
Table of Thermal Conductivity Values (k)
By way of example, the table below lists thermal conductivity values (k) for a
variety of materials, in units of W/m/ C.
Material k Material
Aluminum (s) 237 Sand (s) 0.06
Brass (s) 110 Cellulose (s) 0.039
Copper (s) 398 Glass wool (s) 0.040
Gold (s) 315 Cotton wool (s) 0.029
Cast Iron (s) 55 Sheep's wool (s) 0.038
Lead (s) 35.2 Cellulose (s) 0.039
Silver (s) 427 Expanded Polystyrene (s) 0.03
Zinc (s) 113 Wood (s) 0.13
Polyethylene (HOPE) (s) 0.5 Acetone (I) 0.16
Polyvinyl chloride (PVC) (s) 0.19 Water (I) 0.58
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Dense Brick (s) 1.6 Air (g) 0.024
Concrete (Low Density) (s) 0.2 Argon (g) 0.016
Concrete (High Density) (s) 1.5 Helium (g) 0.142
Ice (s) 2.18 Oxygen (g) 0.024
Porcelain (s) 1.05 Nitrogen (g) 0.024
According to ASTM data, the thermal conductivity valve of DELRIN is in a
range of 0.28 (DELRIN D900P) to 0.36 (DELRIN D1700P) in units of W/m/ C,
and depends on the type of DELRIN C) used in the particular application.
The Scope of the Invention
It should be understood that, unless stated otherwise herein, any of the
features, characteristics, alternatives or modifications described regarding a
particular embodiment herein may also be applied, used, or incorporated with
any
other embodiment described herein. Also, the drawings herein are not drawn to
scale.
Although the invention has been described and illustrated with respect to
exemplary embodiments thereof, the foregoing and various other additions and
omissions may be made therein and thereto without departing from the spirit
and
scope of the present invention.
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